Tyre technology For effective production

Multiplex Extrusion Lines

IN PARTNERSHIP WITH INDUSTRY
KraussMaffei is a premium partner
for the plastics and rubber processing industries
worldwide
Automotive White goods
Whatever you aim to achieve in plastics or rubber
processing, KraussMaffei is your partner. We are
the only company with intensive expertise across
the three main engineering fields. And we have a
strong track record in integrating this expertise to
develop new processes and systems.
Ready for any challenge
Our Injection Moulding Technology Division
supplies machines and systems for standard and
special applications, very large machines and fully
automated solutions. Our main markets are in the
automotive, packaging, electrical, electronics, medi-
cal technology and consumer goods industries.
Our Reaction Process Machinery Division supplies
machines and complete systems for processing
polyurethanes and other reactive materials.
Completing our product portfolio, Tooling
Technologies supplies foam moulds, cutters and
routers. Our customer base is wide, with a focus
on the automotive, construction and white
appliances industries.
Our Extrusion Technology Division supplies
machinery and systems for compounding, for pipe,
profile and sheet extrusion, physical foaming, and
the production of technical rubbers and inter-
mediates for tire production. Machinery from the
company’s range – from single extruders to
Construction Medical / pharmaceutical Electrical / electronics
complete extrusion lines – is used in many
industries, including chemicals, pharmaceuticals,
automotive, construction, furniture and packaging.
People for Plastics
We are the “people for plastics”. We are your
partners from the first exploratory discussion,
through development to commissioning, servicing
and operating your system, and final disposal. At all
times, you are assured of outstanding competence
in planning and engineering, as well as reliable and
fast spare parts, service and support.
Adding value for customers
We put our expertise to work for your success.
With machine ranges engineered for modularity,
we can deliver application-specific solutions
based on our wide range of standard modules and
specially engineered solutions. This strategy offers
customers technical and cost advantages.
Close to customers around the world
As an international company, KraussMaffei has a
presence in all the major markets for the plastics
and rubber processing industries and employs over
3,000 people worldwide. Our sales and service
network keeps us close to all our customers around
the world.
 Combining excellent product quality with
maximum production output – Multiplex
extrusion lines

Packaging

As an expert partner for the tyre manufacturing

industry; KraussMaffei Berstorff delivers complete
leading-edge systems for the production of tyre
components. Our goal is to offer the made-to-measure
solutions you need to succeed in today’s fast moving
competition.

In our product portfolio you find Multiplex extrusion

lines with the highest output-rates in the market.
Proven engineering power, unrivalled technological
expertise, numerous patented developments and
active participation in the production processes of
the tyre manufacturers testify to the innovative
character of our machinery and made us what we
are today: the world leader in this technology.
Multiplex Extrusion Lines
High technology, high quality, high output
The automotive vehicle tyre is a high-performance
precision unit. The requirements of safety, com-
fort, economy and environmental compatibility
demand a high level of quality in every single tyre
component.
For the manufacturer, this means the application of
technologies, which combine excellent quality with
high output.
KraussMaffei Berstorff’s response to this challenge
is the delivery of complete high-tech extrusion lines
for the production of tyre components.
Our know-how matured over decades, our own
patented developments and our active participation
in the innovative processes of the tyre manufacturers
all go to make us an expert partner for the industry.
Tread compound
Undertread
compound
Sidewall
compound
Rim cushion
Seite 4
The demands and expectations of our customers
are met with closely-targeted advice, highly-develo-
ped project management methods, computer-aided
component design and state-of-the-art manufactu-
ring and application-specific commissioning.
Our Technical Centres offer practical pre-contract
support with production-scale machinery and labo-
ratories with inspection and testing facilities. Trials
are conducted under real conditions to secure the
basis for each investment. The result is customer
satisfaction right from the outset.
High-tech extrusion lines with the highest output
rates confirm our position as the world leader in
this technology as all the significant manufacturers
produce their tyres on KraussMaffei Berstorff
machinery.
Tread
Capply
Belt layer 1
Belt layer 2
Sidewall
Carcass
Innerliner
Apex
Bead wire Bead
Multiplex Extrusion Lines
 Multiplex Units for Pre-assembly

Pre-assembly: precision in detail

Pre-assembly defines the level of the production

technology. This is because pre-assembly of
passenger car and truck tyres utilises all the
reserves of rationalisation, whilst simultaneously
raisng the tyre component quality to a high level.

KraussMaffei Berstorff machines are designed in

concept to meet the special demands of the manu­
facture of semi-finished components. Duplex,
Triplex and Quadroplex extrusion sets guarantee
precise combination of the different components,
totally free of air inclusions. The end result is
always more than the sum of the individual parts
– here is component technology in perfection,
allowing significant rationalisation by reducing
the number of working stages on the tyre building
machines.

Extrusion Passenger Truck

· ··
Head Product car tyres tyres
Duplex
Duplex Sidewall + rim strip

·
Cap + base

·
2-component apex

·
Triplex
Triplex Cap, base, wings

·
Cap, base, cushion
Black sidewall, rim strip,

·
shoulder pad
Quadroplex
Quadroplex Cap, base, wings,

··
cushion
2 x cap, base, wings
White sidewall, rim strip,
shoulder pad Wings Cap Base Cushion

Preline Seite 5
Multiplex Lines
Quality and performance
without compromise
All tyre makers are seeking ever-tighter manu­
facturing tolerances, whilst throughput rates are
steadily rising.
KraussMaffei Berstorff extrusion lines are concei-
ved for high product quality and maximum output
and are equipped with extruders of different types
(GE-SC or GE-KS) and sizes.
The modular design makes for rapid reconfigura-
tion to suit the mode of operation – Mono, Duplex,
Triplex or Quadroplex.
KraussMaffei Berstorff Multiplex extrusion sets are
designed in a piggy-back arrangement to achieve
the highest product quality through symmetrical
Flow channels in the Multiplex extrusion head
Seite 6
Pre-assembly of a
Multiplex extrusion set
material flow in the head. In addition, the compact
design makes for real space savings. A further
feature to satisfy the quality requirements is the
special design of the flow channels in the extrusion
head. These ensure a very gentle, even material
transfer from the round section at the extruder
outlet to the rectangular flat form of the profile. In
addition, the changes in direction of the material
flow in the flow channel are kept to a minimum.
All stages of the process are controled by a monito-
ring system, thus ensuring operational security.
Throughput rates of up to 10,000 kg/h or about
30,000 passenger car treads per day are achieved
with these modern extrusion lines.
Multiplex Lines
Preline Seite 7
 M ultiplex extrusion heads and tools
 Versatile and efficient:
systemised head operation
The range of different tyres dictates the require-
ments for changing the compound, dimensions
and programs run on any production line, whilst
the extrusion head determines the quality and
efficiency of the tyre production.
Multiplex extrusion heads from KraussMaffei
Berstorff represent the state of the art with
· working widths up to 850 mm for up to 2 treads
in one production pass
· locking forces up to 10,000 kN
· connection of up to four extruders of different
types and sizes
To achieve rapid change times for different profile
dimensions, KraussMaffei Berstorff have two
solutions:
Seite 8
· Cassette changer unit on the operator side,
consisting of a housing and a vertical sliding unit
on either cassette. One housing is in production,
whilst the other is in the preparation position.
· Double wedge comb to shorten change of the
final die without changing the splice bar. While
the outer wedge comb is opened, the inner one
holds the housing and splice bar closed against
the head.
This minimises scrap and allows rapid restart of
production.
The upper and lower parts of the head can be ope-
ned separately to facilitate cleaning when changing
the compound and to accelerate the changeover.
Multiplex extrusion heads and tools
Easy to clean: extrusion head in opened position Multiplex extrusion head with cassette changer unit
 Accelerator roller train
with blow-off jets

Width
Continuous length Profile measurement
Multiplex Take-off roller train weighing scale scanner
extrusion set with marking unit and width scanner Cutting machine skiver

 M ultiplex complete lines

System technology at a stroke

The better the individual process stages fit together,
the more secure is the flow of the production.
KraussMaffei Berstorff designs complete line con-
cepts to attain perfect interplay of all components
under changing parameters.
Based on our wide experience, we bring together
all elements of the production line into a systemised
technological solution. From the feed units to the
wind-ups – everything from one single source.
Each part mates with the next and every compo-
nent of the line can be matched to the process-tech-
nical requirements of compound and dimensional
changes or changes from cut piece to wind-up
operation. The interface-free configuration of the
machinery ensures constant product quality at
maximum capacity utilisation.

Feed units with Gauging instruments

· metal detectors
· automatic setting of the feed rate
· simple service and maintenance
· continuous weight per meter and weight per piece for
precise weight measurement
· width measurement before and after the cooling unit
· profile scanning for continuous monitoring of the geometry
· length measuring units for monitoring the cut profile lengths
Reject roller train Cross-cutting unit Spray cooling

Manual pick-off roller train – Wind-up stations

cut-piece operation

Marking units for Cooling systems Cementing station

· printing of coloured stripes · units for spray or immersion cooling · to increase adhesion of the
· printing of identification codes splice surfaces
· imprints of numbers and letters

Cutting units (Skiver) Wind-up operation Cut-piece operation

· flying cut or start/stop cut for cut-piece · cassette winders · manual pick-up roller train
operation with the highest cut quality, · spool winders · automatic booking system
length precision and maximum cut rates
per minute, rotary cutting for wind-up
operation
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3 4
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12
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Control and automation
Multiplex Extrusion Lines
Planning and construction of the electro-techni-
cal equipment for the extrusion lines are carried
out in modular form to the latest standards.
Customised configurations can be quickly created
without problems.
The extruder motors are equipped with micropro-
cessor drives, digital actual value access and bus
connector set point provision. This technology
ensures a high degree of repeatability, exact regu-
lation and dynamic screw speed control. All this
has a direct influence on the quality of the extruded
profile. KraussMaffei Berstorff developed control
software mimimises start-up scrap and keeps the
extruded profile within the prescribed dimensi-
onal and weight tolerances during production.
The system continuously reads the weight and
the dimensions of the profile as well as the screw
speed and the stock pressure and temperature in
Seite 12
6 7
13 14 15 16
21
20 22
19 23
WIN CC (Win NT)
each extruder. If the actual process values deviate
from the set points, the process parameters are
corrected individually or, depending on their
proportion of influence on the profile components,
of all extruders. Auxiliary drives are equipped
with low-maintenance three-phase standard motors
and vector-controlled frequency converters. Non-
contact sensing systems such as CCD cameras and
ultra sonic sensors and special digital dancer-type
regulators provide tension-free material transport.
Each system is provided with a digital software con-
trol, which guarantees optimal speed matching with
its adjacent downstream drive. The PLC automation
units of the individual machines are networked via
TCP/IP with each other and with the visual display.
Operator-friendly visualisation and easy-to-use
recipe management facilitate flexible production
planning, high product quality, minimal start-up
scrap and rapid changeovers.
Control and automation
 1 Service 16 PLC customer
2 Host communication
3 Modem 17 Profibus DB
4 Switch 18 AC Drive with
5 OPC server pulse generator
6 Main operator panel Extruder 1 –  4
7 Operator box head 19 AC drive with
8 Ethernet TCP/IP pulse generator
9 Profibus DB Mini Rollerhead
10 Extruder control 20 Heating controller
11 Terminal- and 21 Camera
operator-boxes 22 Scale
12 Feeding for 23 AC Vectordrive
extruder 1 –  4 with pulse generator
13 Feeding for Mini RH Downstream 1...n
14 Head
15 Terminal- and
operator-boxes

Roller-Head lines

Tandem operation for

maximum precision

Roller-Head technology from KraussMaffei

Berstorff combines precision and economy into one:
close-tolerance work for the production of innerliners
and filler strips. The rubber compound is plastified
in the extruder and fed directly to the roll gap of
the two-roll calender via a wide-slot extrusion die.
The calender calibrates the web exactly to the preset
final thickness. This process avoids the formation
of a rolling ball in the calender and thus the risk
of air inclusions. The narrowest of tolerances over
the entire web width and optimal homogeneity of
the compound ensure the perfect tyre innerliner and
filler strip.

Both profiles are doubled with the highest centricity

and absolutely blister-free.

Roller-Head lines Seite 13

SERVICE WORLDWIDE
Service, support and spare parts – when you
need them, where you need them
Rely on us for a fast and competent response to
all your service needs anywhere in the world.
Whatever you need – from troubleshooting or
training to spares or repairs – we’re on the job.
We’re dedicated to supplying service quality on a
par with the outstanding quality of our machines
and systems. We offer far more than spare parts
and hotlines. We’ll work with you to choose the
best and most cost-effective solution for your
production. We’ll help you test new applications
and we’ll plan customized service packages.
All-round service
Our service offering is broad. We’ll configure your
system, install and commission it, train your staff,
plan measures to minimize your downtime risk and
maximize productivity, and carry out maintenance,
repairs and upgrades. You’ll find us fast, reliable
and competent. Our hotline is manned by highly-
trained and experienced service technicians.
If necessary, we’ll get a technician to you quickly.
Remote diagnosis, interfacing directly with your
machine’s control system, can be a practical
alternative. Spares for all important wear parts are
available at short notice. We’re continuously
expanding our service network to speed up spare
parts shipment. Talk to us about the right service
solution for your business.
Customer trials and prototyping in our test lab
The Extrusion Division operates a test lab in Ger-
many and USA fitted with the latest machinery and
equipment. We can run trials and fine-tune pro-
cesses on your behalf. We can work with you to test
and evaluate processes, machines and equipment in
order to identify the best approach for a particular
project. Our highly-qualified application engineers
are there to help you.
Training with high hands-on content
Courses are held in our lab and training centre,
or, optionally, on your premises. We offer
clearly-structured basic and advanced training in
operation, process control and maintenance for
KraussMaffei extrusion systems. On request, we’ll
plan and hold special courses on topics of your
choice. All participants spend a high proportion
of their training working hands-on with original
KraussMaffei Berstorff machines. A well-structured
training program produces skilled operators and
technicians, which will positively impact your up-
time and productivity.
Worldwide hotline
numbers KraussMaffei Phone rubber
Berstorff GmbH technology: +49 172
Hannover, Germany 511 9620
Phone plastics
Customer Service 
technology: +49 172
Phone: +49 511
511 9621
5702-533
Phone service
Email: service-ext.
hotline: +49 172 511
ha@kraussmaffei.
9623
com

Krauss Maffei Italiana S.r.l.

Rezzato, Italy
Phone: +39 030 2590707
Fax: +39 030 2592369
Email: service-ext.it@kraussmaffei.com

BKM Servicegesellschaft OOO

KraussMaffei Berstorff
Moscow, Russia
Krauss Maffei Corporation
Phone: +7 495 9377554
Florence, USA
Fax: +7 495 6265745
Phone: +1 859 2834376
Email: service-ext.ru@kraussmaffei.com
Fax: +1 859 2830290
Email: service-ext.us@kraussmaffei.com

Krauss Maffei Mexico

Mexico City, Mexico
Phone: +52 81 15211604
Fax: +52 55 53081727
Email: ser vice-ext.mx@kraussmaffei.com KraussMaffei Co., Ltd.
Shanghai, China

Krauss Maffei do Brasil Ltda Phone: +86 21 58682662

São Paulo, Brazil Fax: +86 21 58681173

Phone: +55 11 56412273 Email: service-ext.sha.cn@kraussmaffei.com

Fax: +55 11 56419337

Email: service-ext.br@kraussmaffei.com Krauss Maffei Asia Pacific Pte. Ltd.
Singapore
Phone: +65 65 535828
Fax: +65 64 550419
Email: service-ext.sg@kraussmaffei.com

Contacting us by post
If you need to contact any of our Customer Service
international service or spare parts teams KraussMaffei Berstorff GmbH
by post, use this address: An der Breiten Wiese 3-5
30625 Hannover
Germany
KraussMaffei is a premium partner for the plastics and rubber processing
industries worldwide. KraussMaffei machines and systems are used wherever
plastics and rubber are converted into products. As a knowledge-driven
technology company, we build on many decades of experience and a strong
commitment to research and development.

As an expert partner for the tyre manufacturing

industry; KraussMaffei Berstorff delivers complete
leading-edge systems for the production of tyre
components. Our goal is to offer the made-to-

1.0 WE . 1st edition 06/07. EXTH XXX A PRO 06/2007 GB ··· KraussMaffei reserves the right to make technical changes.
measure solutions you need to succeed in today’s
fast moving competition. In our product portfolio
you find Multiplex extrusion lines with the highest
output-rates in the market. Proven engineering
power, numerous patented developments and active
participation in the innovative processes of the tyre
manufacturers testify to the innovative character
of our machinery and made us what we are today:
the world leader in this technology.

KraussMaffei Berstorff GmbH

An der Breiten Wiese 3-5 ··· 30625 Hannover

Phone +49 511 5702-0 ··· Fax +49 511 5619-16
www.kraussmaffei.com